0751050 Forpak

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Project Scope: Production support at Purnell. Expenses paid, labor covered by MFT.
Equipment Summary: (Machine Serial Number:Multiple) Washdown Roll to Sheet system - 2023057
Work Done: Elliot Wong Sunday 3/3: Travel from MSP to SDF Monday 3/4: Arrive onsite by 6, production delayed until ~9. Ran Production till around 2, had to replace rolls, but paper would not feed through side furthest from electrical enclosure. Noticed that the clamping bar on the cutter looked to be too close to the anvil, suspected that clamping bar was loose. Removed cutter and found out that cylinder was completely detached from the rest of assembly. Loctite cylinder and reinstalled knife assembly. Tuesday 3/5: Arrive onsite by 9, production delayed until ~11. Ran several sheets through to ensure knife cut through products, needed to do some tweaks to adjustment on side that was disconnected from cylinder. Ran production for a couple of hours, was getting mostly good cuts, but every once and a while we would have a miss cut. Wednesday 3/6: Arrive onsite by 9, production started around 930 ran well for a couple of hours, but the miss cuts kept happening more frequently. I suspected the blade could need a replacement so Gerry from Forpak went to get the replacement set. When installing the new set, we noticed that the blade would not go past the point where the blade makes first contact with the anvil. We suspected the shoe and anvil were not the same thickness, we used some shim stock from the maintenance team at Purnell. We shimmed the shoe .004" and that seemed to help, although it was still difficult to close the knife assembly compared to the original set on the blade. We were able to do Azco's blade adjustment procedure to get the assembly to cut cleanly though the wax paper and reinstalled the assembly. Thursday 3/7: Arrive onsite by 6, production delayed until ~8. Ran production until ~1130 System was functioning well, had one instance of the unwind not being tight enough so the unwind kept spinning causing a mess of paper. Also had a (fire?) alarm go off and building was evacuated. Continued to run production until ~230 when the knife assembly stopped working again. At this point the knife would not actuate past the point of contact with the anvil, similar to what we saw before we shimmed the shoe. At this point, production was done and we removed the knife assembly again. We attempted to diagnose the issue again and couldn't get past the anvil with the blade. The conclusion was that either the replacement parts were bad or the assembly got tweaked when the one cylinder was disconnected on Monday. The decision was made to sent the assembly back to Azco. Gerry and I had to box up the assembly ourselves, the shipping guy for Purnell had already left for the day, so we went to the UPS store in Louisville to ship the assembly and replacement blades to Azco. Friday 3/8: Returned rental car and flew on early flight back to MSP. Joel Monday 3/18 10-4 MSP to SDF 5-10 put in and removed cutter 3 times readjusting blade until correct. Tuesday 3/19 6:30 - 12:30 remove cutter again and readjusted coupler from cylinder to blade carriage then readjusted blade. reinstalled cutter. 12:30 - 2:30 successfully ran production Wednesday 3/20 7:30 - 11:30am cutter failed to cut to run production despite it being tested ahead of time. pulled cutter readjusted and noticed there was air leaking from valve. turned pressure up and successfully tested. 11:30 - 2pm ran production till the cutter stopped moving quick enough and the plc started faulting. pulled cutter and confirmed one of the cylinders was bad. 2 - 11:45pm drove to Tennessee to get the other cutter to be ready for production on Thursday morning. Thursday 3/21 6:30-4 installed cutter 2 and ran a full production shift with no issues. packed cutter 1 and shipped to mft Friday 3/22 4:30 - 9:30 SDF to MSP Forpak Mike Erickson Monday 4/22/24 (9.25hrs) Travel 5.5hr On sight 2hrs Hardware store 1.0hrs Office work .75hrs Installed jog button and ran wiring. Ran to hardware store to get a drill bit for drilling hole for wiring in jog button. Office work .75hr Tuesday 4/23/24 (10.5hrs) On sight 9.25hrs Hardware store .75hrs Office work .5hrs Wired in jog button and installed new brackets. Moved fan box and rewired fans. Had to run to the hardware store and get a lighter and inspection mirror. Installed proximity switches and needed mirror to see the distance on switches to set them correctly. Had Greg B remote into my computer to add jog button into the program. Also, Greg made some adjustments in the program for better operation. Tested all program changes with the machine and all tested good. Wednesday 44/24/24 (10.25hrs) On sight 1.5hrs Travel 8.25hrs The customer ran equipment last night with product and did not have any issues with our equipment. Arrived this morning and found customers equipment had failed last night and we are not able to run today. Had a meeting with customer and determined that there was no need to stay. Booked a flight out a day early.
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Edit	XID	Part Number	Serial Number	Part Name	Complete	Total Hours	Hours Remaining	Qty	Cost	Price	Discount	Cal Price	On Hand
Edit	72255			LABOR - HOUR ON SITE	Set Complete		0 hrs	0		$285.00
Edit	72256			LABOR - 1/4 HOUR ON SITE	Set Complete		0 hrs	0		$71.25
Edit	72257			LABOR - TRAVEL	Set Complete		0 hrs	0		$160.00
Edit	72258			LABOR - ADDITIONAL CHARGES	Set Complete		0 hrs	0		$0.00
Edit	72259			TRAVEL EXPENSES - CAR	Set Complete		0 hrs	1		$0.00
Edit	72260			TRAVEL EXPENSES - AIRFARE, CHANGE FEES, LUGGAGE	Set Complete		0 hrs	1	$1,291.20	$1,523.62	0.00	$1,523.62
Edit	72261			TRAVEL EXPENSES - HOTEL	Set Complete		0 hrs	1	$717.90	$847.12	0.00	$847.12
Edit	72262			TRAVEL EXPENSES - PARKING, MEALS, GAS	Set Complete		0 hrs	1	$270.00	$318.60	0.00	$318.60
Edit	72263			SERVICE TRIP PRE-TRAVEL PREP FEE	Set Complete		0 hrs	1		$250.00
Edit	72264			LABOR - ENGINEER HOUR ON SITE	Set Complete		0 hrs	0		$320.00
Edit	72265			LABOR - SR ENGINEER HOUR ON SITE	Set Complete		0 hrs	0		$435.00

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	Department	Quoted Hours	Est. Hours	Hours Remaining	Billed Hours	xid	Start Date	Resource(s) Assigned	Assignment	History
Edit	Field Service	0	0	0	0	12178

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			**ALL ITEMS BELOW ARE INCLUDED IN COSTING & PRICING PN 9740001**